Installation Guide - Soda Dispenser Depot

Installation Guide
Counter Electric
Dispenser System
Start-up Video: http://youtu.be/c_eeYPQz7tU
©2013 SodaDispenserDepot.com - All rights reserved.
Table of Contents
1.
2.
3.
Preparing for Installation
3
Water Supply
6
Installing the Components
10
1.1
1.2
2.1
2.2
3.1
3.2
3.3
3.4
Unpacking & Inspection
Tools Needed
Volume, Pressure, & Quality
Connecting the Water Supply
Installing the Dispenser
Installing the Drain
Connecting the CO2 Supply
Connecting the Syrup Supply
4. Start-up Procedures
21
5.
Sanitation
34
6.
Troubleshooting
37
Preparing for
Installation
Chapter 1
3
1.1 Unpacking & Inspecting
Upon receiving your system remove it from the shipping carton or
pallet.
Required Items & Parts
Unpack all parts. Make sure all
required items and parts listed (left)
are present and in good condition.
If any parts are missing or damaged,
notify our office immediately.
Optional Items
*
* Not all systems include this item
4
1.2 Tools Needed
1. Pliers
2. Flathead Screwdriver
3. Crescent Wrench
A bucket and rag
are also useful to
have, if needed.
5
Water Supply
Chapter 2
6
2.1 Volume, Pressure, & Quality
Since a soft drink is approximately 5 parts water to 1 part syrup,
having an adequate, clean water supply is absolutely essential.
There are 3 important areas of focus with your water supply:
1. Volume
• The inside diameter of your main water supply tubing
must be a minimum 1/4” if connected to your water source
within 10’ of the carbonator.
• If your carbonator is more than 10’ away from the water
source, a minimum 3/8” inside diameter is required.
Anything less then this will starve the carbonator pump and
create noise within the pump, poor carbonation, and cause
premature failure of the carbonator. Do NOT use ice maker
tubing!
• Food grade braided nylon, copper, or stainless tubing is
acceptable for your main water supply.
7
2. Pressure
• High water pressure affects the carbonators ability to
carbonate properly. Ideal water pressure range is 35 – 55
psi. If water pressure exceeds 55psi, the carbonator will NOT
carbonate properly.
• Water pressure above 55psi. (most city
water is above 55psi.) will require a water
pressure regulator.
• If the water pressure is irregular or below
35psi. a water booster will be necessary.
3. Quality
• Mineral deposits & sediment (found in most city water
supplies) get caught in the carbonator rotary vane pump,
and in the check valves as well as other areas of the system
causing leaking and or failure.
• A water filter is recommended to remove unwanted silt,
sand, smells, & other undesirables. This will give the highest
quality product results as well as lengthen the life of your
soda system.
8
• When a water filter is used, it is
important that it has a flow rate of
100 gallons per hour and MUST be
flushed BEFORE it is connected to
the soda system.
Cartridge and Inline water filters
NOTE: Water supply should be connected pre-water softener, not
post. Using softened water will adversely affect carbonation.
2.2 Connecting the Water Supply
The main water connection on your system is clearly tagged. Your
water supply line will run to the carbonator pump.
We use a 3/8” fitting (not metric) for this connection.
NOTE: If you have a non-carbonated flavor or plain water coming
from your dispenser, you will need to “tee” your main water supply.
Once you have established your water supply source, it is
important to thoroughly flush this line for a few seconds of any
debris, scale, mineral deposits, and any other impurities that
may be in the lines. The smallest amount of debris can easily get
lodged in a check valve or in your dispenser causing dripping,
leaking, and failure.
NOTE: Water connections directly connected to potable water
supply should be sized, installed & maintained according to federal,
state, & local laws.
9
Installing the
Components
Chapter 3
10
3.1 Installing the Dispenser
Dispenser Installation
There are a couple different ways to install your dispenser.
You must decide which way is best
to run your product tubing. You have
access through the bottom of the
dispenser to go through an opening
in your counter. There is also an
opening rear of the dispenser for
routing the tubing out of the back.
11
3.2 Connecting the Drain
NOTE: The cup rest drain needs to be connected before any testing
is performed.
There will be 2 drains on your counter electric dispenser:
• The cup rest drain can either be capped off for manual
draining/cleaning or you can hard plumb it into a proper floor
drain. If you decide to cap it off, you’ll need a bucket when it
comes time to perform tests.
• The water bath drain is to be closed at all times unless you are
taking the dispenser out of service. This drain will be located on
the bottom or behind the front splash panel, depending on the
model of your dispenser.
12
3.3 Connecting the CO2 Supply
1. Place CO2 cylinder where it can be
easily retrieved for refilling. Secure
the tank with a safety chain to
prevent the tank from falling over.
2.Connect primary CO2 regulator to CO2
cylinder. Use a fiber or plastic washer
between the primary nut & stem and
the tank neck (right).
3.Tighten the CO2 nut on the regulator with an adjustable wrench.
If you have separate primary &
secondary regulators (left) with your
system go to step #4
If you have a triple gauge regulator
(right) skip to:
“Triple Gauge Regulator Installation”
13
4. Using the ¼” high pressure
tubing, attach the ¼” swivel
nut that is marked “ to primary
regulator gas out” to the
bottom of the regulator. Make
sure the white nylon flare
washer is between the swivel
nut and the brass flare fitting
located on the bottom of the
primary regulator.
5. Tighten the swivel nut with an adjustable wrench.
6. Locate where you want to mount the secondary regulator and
syrup pumps.
7. Attach the CO2 tubing swivel
nut end that reads “to secondary
regulator gas in” to the right male
flare fitting on the secondary
regulator. Make sure white
flare washer is installed before
connecting. Tighten swivel nut with adjustable wrench.
8. Attach the remaining swivel nut end of the CO2 line that reads “
to carb tank CO2 gas in” to the carbonator tank. Make sure white
14
flare washer is installed before connecting. Tighten swivel nut
with adjustable wrench.
WARNING: DO NOT TURN ON THE CO2 SUPPLY AT THIS TIME
Triple Gauge Regulator Installation
Triple gauge regulators are both
primary & secondary regulators
attached together.
You will have two separate CO2 gas
lines for this type of regulator.
Attach the swivel nut on the CO2 line that reads “to primary
regulator gas out” to the brass male flare fitting on the bottom
of the primary regulator. White flare washer MUST be installed
between these two fittings. Tighten swivel nut with wrench.
Attach swivel nut on the opposite
side of the CO2 line that reads “to carb
tank CO2 gas in” White flare washer
MUST be installed between these
two fittings. Tighten swivel nut with
wrench.
15
Attach the swivel nut on the CO2 line
that reads “to secondary regulator gas
out” to the brass male flare fitting on
the bottom of the secondary regulator.
White flare washer MUST be installed
between these two fittings. Tighten
swivel nut with wrench.
Attach swivel nut on the opposite side
of the CO2 line that reads “to syrup
pump CO2 gas in” White flare washer
MUST be installed between these
two fittings. Tighten swivel nut with
wrench.
WARNING: DO NOT TURN ON THE CO2 SUPPLY AT THIS TIME
16
3.4 Connecting the Syrup Supply
Bag-N-Box is a plastic bag filled with
syrup encased in a box.
There is a connection receiver at one
end of the bag.
A syrup pump with a clear piece of
tubing with a bag in the box connector
attached to it is connected to the
receiver. (see picture below)
Syrup is pumped out of the bag,
moves through the syrup pump and is
pushed toward the dispenser. There are different style connectors
for different manufacturer’s products.
17
Pump Operation
The syrup pump is propelled by gas (or air)
pressure. The pressure of the syrup leaving the
pump is equal to the gas pressure feeding or
driving the pump.
The pump will continue
to run until the pressure of the
outbound syrup is equal to the
inbound gas pressure.
When the pressure drops in the
syrup line to the dispensing valve, the pump will activate and
18
continue until the pressure is equalized. This will happen almost
every time a drink is poured from the valve.
Installing Bag-In-Box Syrup Pumps
1. Place your syrup boxes as close as possible to the syrup
pumps. Under 10 feet is ideal.
2. Mount syrup pumps to your desired location.
3. Uncoil syrup line tubing from cooling device to the syrup
pumps.
4. Connect the syrup pump fitting on each line to each pump.
(See pictures of pump types below)
19
5.Attach each syrup pump bag in box
connector to each syrup box.
6. If you DO NOT have all of syrup
boxes (1 for each syrup pump)
disconnect the gas CO2 fitting from
the pump so it does not activate
that pump when you start the system. Allow it to dangle loosely.
20
Counter Electric
Start-up Procedures
Chapter 4
Start-up Video: http://youtu.be/c_eeYPQz7tU
21
Counter Electric Water Bath Start-up
The counter electric dispenser is cooled by a water bath.
The water bath area is under the
lid. You must fill the water bath
with tap water to about 3/4 of an
inch from the top of the unit (yes,
all that stuff ends up under water).
This will require about 10 gallons
of water.
Do NOT turn the counter electric
dispenser ON without water in
the water bath! The water bath is
where the unit makes a block of ice
used to cool the drinks. It will take
about 4 hours for the first ice bank
to form and the unit to shut off.
After that, it will cycle periodically,
maintaining a full ice bank.
NOTE: This water is only used for cooling the drinks; you will
never drink this water. From time to time, check the water level
and fill if low.
22
Water, syrup, and electric lines all come into the unit and run
behind the front splash panel behind the valves. It is best to
bring the lines straight back or under the unit, to keep them from
kinking.
Connect all lines and turn on the water supply BEFORE turning the
power switch to the “ON” position.
1.Fill up the water bath two (2)
inches from the top of the
water fill hole.
2.Put your finger in the water
bath fill hole. The water should
be halfway up your finger.
3.Plug the dispenser into your power
supply. If slurping noise is heard,
water level is too low.
4.Allow the machine to harvest ice for the next several hours.
23
Standard Carbonator Start-up
1.Turn water supply to the carbonator
ON.
Water supply tubing and valve are
not included, so your water supply
connection may look different than
this picture.
2. Start filling carbonator tank by
releasing the pressure relief valve
located on top of carbonator tank
(see figure #1).
This will allow air to escape while
the tank fills with water. Hold
pressure relief valve open until
water spurts out of valve opening.
3. Close pressure release valve.
4.Check for water leaks. Inspect
all connections where water is
run (example: carbonator, soda
fountain or gun, all tubing lines
carrying water).
24
Figure #1.
5.Plug carbonator in to power
source.
Do NOT expect the carbonator
to start running because it is
already full of water. Only after
dispensing soda water will
the float in the tank sense the
water level drop and activate the motor and pump.
This procedure will be performed later.
25
CO2 Gas Introduction
6.Prepare for CO2 gas
introduction to the system.
Make sure the adjusting screw
(see figure #2) & screw lock
nut (see figure #3) are not
tightened but are unscrewed
and loosened.
This is performed by turning
them in the counterclockwise
direction. This allows you to
introduce the gas in stages.
Figure #2.
7.Turn CO2 tank valve on. Turn in
counter clock wise direction.
8.Set adjustment on primary
Figure #3.
regulator by turning adjusting screw in the clock wise direction
until needle on primary dial reads 100 psi.
9.Check for CO2 gas leaks by spraying all connections where gas
runs through tubing with a spray bottle filled with a mild dish
detergent mixture (1/2 water & 1/2 detergent).
26
If leaks are found (bubbling;
see figure #4), make necessary
adjustments to clamps or
fittings until bubbling stops
(see figure #5). Tighten lock
nut.
Figure #4.
Do NOT adjust secondary
regulator, yet!
10. Purge air from tubing
by activating each valve
separately.
Figure #5.
11. Recycle carbonator allowing
the proper blend of gas &
water levels in the carbonator
tank by dispensing soda water
from one of the valves (see
figure #6) until carbonator
motor (see figure #7) starts.
Figure #6
Spitting or erratic water flow is normal while air purges from
27
the system. STOP dispensing
water until carbonator finishes
recycling (motor turns off).
Figure #7.
NOTE: Normal carbonator recycling does not exceed 60 seconds.
If your carbonator is taking longer than 1 minute to recycle
(motor turns off), unplug it immediately!
Perform recycling process 3 times. By the 3rd time you will
notice a strong effervescence (bubbling) in the water.
You are now ready to introduce syrup to the system.
NOTE: ALL syrup pumps must be attached to a bag in box syrup
before allowing them to be started. If you do NOT have a syrup
box attached to each syrup pump you MUST disconnect the fitting
that supplies gas to the pump (see figure #9).
12. Turn screw on the secondary regulator clockwise to allow gas
to pass and be sent to drive the syrup pumps
(figure #8).
While turning the screw you will see the needle on the dial
28
rise. As the pressure rises you
will begin to hear popping
coming from the syrup pumps
signifying their activation. You
will also see syrup moving
from the syrup box up the
BIB tubing towards the syrup
Figure #8.
pump.
Continue adjusting regulator to 55 psi
NOTE: Syrup pumps DO NOT continually
run endlessly, they will push syrup to your
dispenser and stop when pressure you
have set the secondary regulator to has
been achieved.
If your syrup pump does NOT shut off
after a minute of setting your secondary
regulator, disconnect the syrup pump
that is continually running by removing
the gas fitting from the active pump (see
figure #9).
Figure #9.
Activate each flavor to allow syrup to flow. You will hear the
syrup pumps popping during this process (see figure #10).
29
Before
After
Figure #10.
13. Adjust each flavor for proper syrup and water (carbonated
or plain) ratio. This can be done to taste or with a brix kit.
Adjusting screws for syrup and soda water are found on the
black triangular manifold.
Adjusting Syrup to Soda Water Ratio (Brixing)
Brixing Standard Soda Fountain Dispenser Valves
Adjust each valve for proper syrup & water (carbonated or plain)
ratio. This can be done to taste or with a brix kit.
Remove each valve cover to
expose adjusting screws for
syrup & soda water.
Left side adjustment is for soda
water or plain water the right
30
Flomatic valve
side is for syrup increase or decrease.
Cornelius UF-1 valve
Lancer valve
Detailed Flomatic Valve Brixing Instructions
Two simple adjustments are all you
need to brix the Flomatic valves. You
will need a Flomatic S tube syrup
separator, 5/32 inch hex wrench,
watch and brix cup. Place the S-tube
syrup separator over the syrup diffuser and you are ready to begin.
You need not remove the nozzle.
Clock-wise movement of the brix nut
adjustment screw increases the flow
rate and vice versa. Restrict the flow by withdrawing the brix nut
adjustment screw as far as it will go (turn counterclock-wise). At
this point the flow will be at a minimum.
31
The 424 or 324 ceramic flow controls
can be adjusted from 1.5 oz. /sec.
to 3.0 oz. /sec. Turn the soda brix
nut adjustment screw five full turns
clock-wise and the flow rate should
be close to 2.5 oz/sec. You will need
to fine tune from there. For fast flow,
continue adjusting the valve until
you get 7.5 oz. of soda in 3 seconds.
Once the soda flow rate is set, then
establish the syrup ratio in exactly
the same way.
The 464GP ceramic flow controls can be adjusted from 2.0 oz./
sec. to 4.0 oz./sec. Turn the soda brix nut adjustment screw five
full turns clockwise and the flow rate should be close to 3.0 oz./
sec. You will need to fine tune from there. For fast flow, continue
adjusting the valve until you get 9.0 oz. Of soda in 3 seconds.
Once the soda flow rate is set, then establish the syrup ratio in
exactly the same way.
Most brix cups are calibrated for a standard brix ratio. Adjust the
syrup flow with movement of the adjusting screw until the desired
ratio is established. Some Flo-matic valves are equipped with a
flow washer on the water side instead of flow controls. In that
case, it is not necessary to set the flow rate. Simply set the syrup
ratio and you are done.
32
Flomatic juice valves may combine with a flow washer on the
water side. The syrup side may be manufactured with a flow
control or metering screw. The metering screw turns clockwise to
close and counter clockwise to open. The screw does not have a
stop; be sure not to withdraw completely when under pressure.
33
Sanitation
Chapter 5
34
Prepare a large bucket with warm to hot tap water.
Mix sanitizer packet (1 packet to
each 2 ½ gallons of water)
You may also use liquid bleach
(unscented) ¼ oz. bleach to each
gallon of water.
If you have Coke or Pepsi bag in
box connectors (right), you will
need to open the spring loaded
safety valve to allow liquid to draw
through the bag in box connector.
Pepsi and Coke BIB connectors
You can also remove the syrup BIB
connector from the clear suction hose on the syrup pump to
allow sanitizer to pass. Reconnect BIB connector with a standard
worm clamp at the completion of
sanitizing.
If you have the grey generic style
connectors, you can remove the
tan cap (right) to allow sanitizer to
pass.
35
If you have access to an empty syrup box, cut the bladder
connect off (see pictures below). This will allow you to attach it
to your BIB connect during flushing & sanitizing.
Put each syrup pump suction hose in the sanitizing solution and
activate dispenser until sanitizer flows freely from the nozzle.
36
Troubleshooting
Chapter 6
37
PROBLEM
QUESTION
SOLUTION
Nothing happens when the
beverage valve is activated
Is the dispenser plugged in?
Plug into wall receptacle
Is there power to the electrical
outlet?
Restore power to the outlet
Is the valve switch defective?
Check and replace the valve switch
Is the valve properly connected?
Ensure the power wires to the
switch are connected
Is there product going to the
beverage valve?
Turn on the valve backblock
shut-off
Is key switch turned off?
Turn ON the key switch
Is the carbonator plugged in?
Carbonator must be plugged in
Is the water supply turned on?
The minimum water supply must be
provided
Is the CO2 supply on?
Check the CO2 tank to see if it is
full and turned ON. If it is empty,
replace or refill it
Is the CO2 pressure set correctly?
The CO2 pressure to the carbonator
must be set between 100-105 PSI.
Check and set all system pressures
to the correct settings.
Is an obstruction in the water line?
Remove the obstruction
Are the water lines connected
properly?
Reconnect water lines correctly
Do you have enough CO2 gas in the
CO2 tank?
Replace or refill CO2 tank
Do you have syrup?
Check and replace any empty boxes
of syrup
Are system pressures set correctly?
Adjust and reset pressures to their
proper settings
Are the syrup connectors properly
connected?
Remove the connectors and
properly reinstall them
Only syrup is dispensing from the
valves
Only water is dispensed at all
beverage valves
38
PROBLEM
QUESTION
SOLUTION
Only water is dispensed at one or
two valves
Is an obstruction in the water line?
Remove the obstruction
Are the water lines connected
properly?
Reconnect water lines correctly
Is the backblock shut-off closed?
Check the backblock shut-off
behind the valve. If it is closed,
open the backblock.
Is electricity getting through the
valve solenoid when energized?
Repair or replace the wiring or
solenoid coil
Are the connectors to the syrup
clean and properly attached?
Clean the syrup connector and
correctly attach the connector to
the syrup connector
Is the syrup system obstructed or
lines installed improperly?
Reconnect the lines properly or
remove the obstruction to allow
syrup to flow.
Do you have a full box of syrup?
Replace if necessary
Are the Bag-in-Box (BIB) syrup
pumps operating?
Check all connections
Are your syrup lines hooked up and
unobstructed?
Check ‘syrup out’ lines designated
for these valves
Is CO2 pressure to the carbonator
properly set?
The CO2 pressure to the carbonator
must be set between 100-105 PSI.
Check and set all system pressures
to the correct settings.
Is the carbonator air locked (all CO2
and no water in the tank)?
Turn off carbonator and CO2.
Release vent on the tank until
water comes out. Turn carbonator
and CO2 on.
Is the inlet water pressure to the
carbonator above the maximum
50 PSI?
Minimum inlet water pressure is
35 PSI — 50 PSI maximum. Install
water regulator or booster pump to
maintain proper pressures.
Poor carbonation
Continued on next page...
39
PROBLEM
QUESTION
SOLUTION
Poor carbonation (continued)
Is the carbonator inlet water
temperature too high?
Inlet temperature of the water to
the carbonator should be no more
than 74 degrees Fahrenheit
Do you have CO2 gas?
Replace or refill CO2 tank
Is the dispensed beverage
temperature warm?
Lower beverage temperature by
checking water bath temperature
Is cooling device working properly?
- Check if ice bank has formed
around remote cooling lines
- Check for proper water level
- Check power to refrigeration deck
Is ice in the cup?
Ice to your carbonated beverage
is necessary to maintain optimum
beverage quality
Is there any residue of cleaning
agents (dish detergent) in the cup?
Any type of cleaning detergent
residue will reduce product quality
Do you have enough CO2 to run the
syrup pumps?
Check amount of CO2 in tank —
Replace or refill your CO2 supply
Are your system pressures set
correctly?
Check and correctly set all system
pressures
Do you have a sufficient supply of
syrup?
Replace empty syrup boxes
Is the brix of the valve set correctly?
Brix all beverage valves
Beverage tastes sweet
Is the brix of the valve set correctly?
Brix all beverage valves
Beverage has an off-taste
Is the brix of the valve set correctly?
Brix all beverage valves
Is the syrup supply fresh?
Most syrups should be used within
90 days of the manufacturer
Is the water supply filter fresh?
Change the filter
Is water supply tubing from main
water supply NSF and non-toxic?
Use only NSF certified and
non-toxic food grade nylon,
copper, or stainless tubing for your
main water supply
Are the CO2 system pressures
correct?
Check and adjust any pressures and
inconsistent regulators
Beverage tastes weak
Beverage valve does not maintain
brix
40
PROBLEM
QUESTION
SOLUTION
Beverage valve does not maintain
brix (continued)
Is the BIB syrup pump holding
pressure?
Repair or replace BIB syrup pump
Are incoming water pressures
constant?
Add water booster pump or water
pressure regulator to maintain
proper brix
Is drink being drawn correctly?
Make sure cup is tilted with product
flowing down the inside of the cup
Is the dispensing nozzle or valve
dirty?
Clean dispensing components
Is soft water being applied to the
system?
Do not use carbonated softened
water for beverage systems
Is the CO2 system pressure to the
secondary regulator high?
Reduce pressures to the
recommended settings
Is the drink too warm?
Make sure the inlet temperature of
the water to the carbonator does
not exceed 74 degrees Fahrenheit
Is the valve lever (if equipped)
sticking?
Replace or adjust the beverage
valve lever to correct
Is the push button actuator sticking?
Replace or adjust the beverage
valve actuator
Dispensed beverage is warm
Has the ice bank frozen completely?
Give the dispenser about 4 hours to
freeze the water bath after start-up
Carbonator does not operate
Is main water supply pressure too
high?
Water supply pressure must be
between 35-50 PSI
Is the water turned on and the CO2
gas pressure set between 100-105
PSI?
Restore CO2 supply to the
carbonator within proper limits
Is electric power supplied to the
carbonator?
Restore electricity to the outlet
that supplies the carbonator with
power
Is the water level control or float of
the carbonator operating properly?
Repair or replace according to
instructions provided by the
carbonator manufacturer
Unusual amount of foaming of
finished product
The beverage valve continues to
operate after released
Continued on next page...
41
PROBLEM
QUESTION
SOLUTION
Carbonator does not operate
(continued)
Is the inlet water pressure to the
carbonator above the maximum
50 PSI?
Minimum inlet water pressure is
35 PSI — 50 PSI maximum. Install
water regulator or booster pump to
maintain proper pressures.
BIB syrup pump will not start
Do you have syrup connected to the
inlet hose of the pump?
Replace syrup box
Is ‘syrup out’ tubing kinked or
obstructed?
Remove the obstruction or
straighten the line
Is the connector to the Bag-in-Box
syrup properly connected?
Remove and properly reconnect the
BIB connector
Is the CO2 supply interrupted?
Check CO2 supply — Replace, refill,
or turn on if necessary
Is the gas pressure to the pump
correctly set?
Adjust gas pressure to the
recommended setting for the
product — Make sure CO2 fitting is
properly inserted
Is a beverage dispensing valve
open?
Open beverage valve to allow syrup
to flow through the system
Is the BIB syrup pump air locked?
Make sure BIB pumps are installed
with the outlet port on top
Is the syrup BIB connector properly
connected?
Remove and correctly reconnect the
BIB connector to the BIB syrup box
Is the tubing from the BIB syrup
box to the pump full flow and not
kinked?
Remove/repair kink or replace hose
Are the gas or air pressures supplied to the pump correct?
Check and correct any incorrect gas
or air pressures
BIB syrup pump operates but does
not pump syrup
BIB syrup pump does not supply
enough syrup
42